Prefabricated building construction



c. D. KEELY 2,775,794

Jan. 1, 1957 I PREFABRICATED BUILDING CONSTRUCTION Filed Dec. 1, 1949 4 Sheets-Sheet 1 l7 /7 /7 7 as 1957 c. D. KEELY PREFABRICATED BUILDING CON STRUCTION 4 Sheets-Sheet 2 Filed Dec. 1, 1949 lil ll ll Zhwemor CZ FFa/Ew 0. KEEA X zlmul a wuwr (Ittorne t A \X Jan. 1, 1957 c. D. YKEELY 'PREFABRICATED BUILDING CONSTRUCTION 4 Sheets-Sheet 3 Filed Dec. 1, 1949 Snnentot CZ/FFO/QQ ,9 K554 Y attorneys 7 c. D. KEELY PREFABRICATED BUILDING CONSTRUCTION Jan. 1, 1957 4 Sheets-$heet 4 Filed Dec. 1, 1949 III\ IIIIIII'IIIIIIIIVIII Ihwemor CA/FFOIQ fi, 4 1554 Y 7 d Gttorney j United States Patent 2,775,794 PREFABRICATED BUILDING CONSTRUCTION Clifford D. Keely, West Englewood, N. J.

Application December 1, 1949, Serial No. 130,486

2 Claims. (Cl. 20-2) My present invention relates to an improved prefabricated building construction with particular reference to single room dwellings or other form of shelter, and to an improved method of erecting same.

In general it is an object of my invention to provide a low cost prefabricated building characterized by simplicity of construction and ease of erection. More specifically it is an object to provide an improved form of construction in which a plurality of wall segments or panels are had, adjacent pairs of which are secured one to the other by frictional engagement with a stud in which the panels will be held with a minimum of nails, bolts or other similar securing means.

1 A further object is to provide such a construction in which the wall and roof segments are supported by the studs.

Another object is to simplify the method of erecting such housing.

A still further object is to provide a structure which instead of resting upon a preferably concrete floor is (removably) supported by attaching devices embodied therein and secured to the wall studs already mentioned. Thereby the improved structure, when temporarily supported from the ground, serves as a mold for the concrete pad constituting the floor. A further result is that the bottom edges of the walls are maintained out of contact with the ground, and are thereby less subject to attack from moisture, termites, etc.

A still further object is to provide a plurality of wall panels-more than 4 and preferably more than 10-a method being provided of simultaneously tightening all the frictional panel and stud connections after which the wall panels are locked in place by means to be hereinafter disclosed.

A still further object is to provide an improved roof including improved means for securing the inner or upper ends of the roof rafters.

Other objects of my invention and advantages thereof will be apparent as the description proceeds and the features of novelty will be pointed out in the appended claims.

For the best understanding of my invention, reference may now be had to the following detailed description taken with the accompanying drawings, of which:

Fig. 1 is an elevational view of an illustrative embodiment;

Fig. 2 is a plan view with the greater part of the roof removed and illustrating an adaptation to a one room dwelling;

Fig. 3 is a view in vertical section of the improved building, taken on section 33 of Fig. 2;

Fig. 4 is a view in vertical section of the top or ventilating portion of one form of roof;

Fig. 5 is a view in vertical section of a fragment of a modified form of roof;

. Fig. 6 is an enlarged fragmentary view of a roof detail as seen in side elevation and showing one manner of finishing the lower edge thereof;

M" a C6 Fig. 7 is an enlarged fragmentary isometric view showing the door and window construction;

Fig. 8 is a fragmentary sectional view of that portion of the construction seen in Fig. 7, taken on line 8-8 thereof;

Fig. 9 is a perspective view of the door sill seen in Fig. 7;

Fig. 10 is a view in vertical section showing the manner of securing the studs at both bottom and top;

Fig. 11 shows a detail of a lower stud portion and adjoining panels and stay wires;

Fig. 12 is a view of a panel and adjacent studs and shows one arrangement of a window pane and holding means therefor;

Fig. 13 is a view in section taken on line 1313 of Fig. 12;

Fig. 14 is a view on line 1414 of Fig. 12;

Fig. 15 is a view on line 1515 of Fig. 12;

Fig. 16 is a view of the same detail as Fig. 6 but showing an alternative construction in which fewer screws are needed; and

Fig. 17 is a view in section on line 17--17 of Fig. 16.

Referring now to the said figures in detail, my improved building consists of a plurality of wall segments or panels 1 of a number more than 4 as to afford the size required. Desirably said panels are of the same width and hence interchangeable. In the construction shown by way of example 22 panels inclusive of the door are employed. While said panels may be constituted of various materials, I prefer the use of structural heat insulating material, as for example fiber board of various types, especially those that are Weatherproof. Such material is of limited structural rigidity for the thickness used, and for this reason the width of said panels should not be too great. Preferably the upper portions of a majority of the panels are interrupted to form a lower section 1 and an upper section 1 (Fig. 13) to provide space for window panes (shown as 2, 2 33 to be hereinafter more fully described). The several panels when assembled form a building of equilateral polygonal form or crosssection, such panels being secured together and supported by studs 3, which are mortised at either side as at 4 and 5, Figs. 12 and 15 to receive and form a tight fit with the edges of the panels. It will be noted that structurally said studs are in effect I-beams, whereby the removal of the material to form the mortises results in little or no loss of strength. Preferably each panel is tapered slightly from bottom to top (thus being an isosceles trapezoid) so that upon erection it may have a slight inclination to the vertical, as seen in the figures, whereby the entire load including snow load of the structure will tend to compress and tighten it.

Preferably each horizontal edge of each panel 1, 1, 1 is provided with a lower bead 5 and upper bead 5 each mortised to accommodate the panel, thereby adding to the compressive strength and enhancing the appearance of the panels.

In order to erect the building a foundation is first prepared, as by pouring a concrete ring 6 (Figs. 2 and 10) of such inner diameter as to afford a support for the panels. In lieu of the ring 6 (Figs. 2 and 10) a temporary support or foundation for each stud may be formed in any suitable manner as by drawing a circle on the ground, locating the stud positions thereon and there, when necessary, driving small stakes (not shown) into the ground, or board pads may be used in lieu of the stakes. The various supports having been placed in position and properly levelled, or the ring 6 having been poured, the erection of the building is commenced by filling the panels into the studs. In the case of a windowed panel the following procedure may be followed:

The lower panel 1 is fitted with the mortised studs 3 at either side thereof, panel 1* (and the succeeding one 1 being already provided with a mold piece and a mold piece 5 for the upper and lower horizontal edges thereof respectively. Then the upper panel 1 is slid to its top position (being insertable through the window opening due to the inclination toward one another of the top ends of adjacent studs 3), a window opening bottom sill cross piece 601 inserted (Figs. 13, 14), then window opening top header cross piece 632 inserted, the same being held the correct distance apart and locked in position by vertical spacer strips 34 and 35 the latter together with outer members 601, 602 being fastened in place by suitable screws or nails as seen in Fig. 13. The Window panes are inserted after the building is erected as will be hereinafter described. After the first window panel has been thus located, the next panel is similarly built up. The polygon is completed by the insertion of the door sill 7 and of top piece 8 of similar shape, such members being preferably of the thickness of the studs 3, but provided with tongues 9 which fit into the mortises 4, 5 of the studs.

Having completed the sides of the polygon the structure is tightened up by forcing the edge of the panels into the mortises of the studs. One way of doing this at the base is by means of the Wires shown in Fig. 2. As shown in this figure and also in Fig. 10, each stud is provided at its lower end with a bolt 10 which extends therethrough and projects somewhat into the interior of the enclosure. Engaging behind nuts 12 of alternate bolts 11 is a tie wire 11. Similarly a wire 11" engages the other bolts. Then by screwing in the nuts 12 the panels are forced further into the mortises of the studs and a symmetrical shape is had. Alternatively a wire 12 may be secured on the outside of the structure below the head of the bolts 10, and the same tightened by means of a turn buckle not shown. This may be removed later when the studs are anchored to the concrete pad to be described.

The structure thus having been tightened at the bottom, the top is also tightened, preferably by means of a Wire tie ring 13 extending around the structure at the top thereof, and tightened by a turnbuckle (not shown). This tie ring remains permanently.

The wall structure now having been assembled and tightened, the roof is then assembled in place. Desirably the roof is substantially of the same type construction as the side Walls and consists of panels 17 of isosceles trapezoidal shape secured by double mortised roof studs or rafters 18. To assemble the roof, four rafters 18 may be first assembled by joining one end to a preferably flanged ring 19, Figs. 4, 5, such four rafters being spaced approximately 90 apart. They may be secured to said ring 19 by screws not shown passing through said ring and into the rafter ends. Then intermediate rafters are assembled and the trapezoidal roof panels 17 slid into place in the mortises of adjacent rafters. The roof as a whole assumes substantial strength and rigidity upon the insertion of the last roof panel. Collar 19 may be provided With ventilating openings and closures (both not shown) and also with a top either in the form of a cone 19 (hinged at 20 and adjustably held at 21) or with a flat top 19 Such covers or tops may be made of transparent material if desired. In Fig. 3 the collar 19 is shown omitted, in which case the initial four rafters used to start the assembly may be supported temporarily by wooden pieces not shown.

it is desirable for the rafters 18 to register with the top ends of the studs 3, the rafters overhanging the side walls and being secured to the studs by means of long screws 22 each passing through a drilled hole in a rafter into the top end of the registering wall stud, or by means of angle irons and screws, not shown, it being noted that the tops of the studs 3 have the necessary bevel, as shown. It will be further noted that in this form the screws 22 pass through the walls of the mortise and into the panels, both of the side Walls andthe roof thus further securing both sets of panels in place. However, the use of the screw 22 in lieu of the angle iron is preferred since fewer screws are required.

Preferably the ends of the roof panels 17 have secured thereto spacer bars 24, Figs. 1 and 6, such bars preferably being tapered at either end, as shown, and suitably secured in place. In Fig. 6 screws 24 are used which pass through the ends of said bars and into the mortise Walls of the rafter 18 and of the panels 17. Alternatively the adjacent ends of the bars 24 are se cured by a metal clip 26 of L cross section (Figs. 16 and 17) which is held in place by means of screw 26 which engages centrally of the rafter 18. One edge of the angle clip 26 can also engage in a saw cut in the rafter, as seen at 27, Fig. 17. Thus the spacer bars 24 effectively hold the roof panels straight and prevent edge sagging, besides enhancing the appearance of the building.

The structure, including the roof, now having been assembled and tightened, the studs having been finally positioned at bottom by hammer tapping, inwardly or outwardly, to obtain true alignment, the door may now be laid, formed preferably of a concrete slab or pad 30, poured desirably on a layer 31 of asphalted paper or other moisture resistant material and covering the wires 11. The slab 30 which completely fills the floor space bounded by the panels, thus is effective further to suspend the panels in place by engaging the bolts 10 and nuts or anchor shields 12. On the other hand if it is desired to knock down the structure the panels may be separated from the concrete body by unscrewing the bolts 10 from the outside, etc.

Figs. 12, 13 and 14 show a form of window construction wherein a pane of glass 33 is used of a width slightly greater than the distance between the adjacent studs 3, the same being insertable into the opening because of the mortises 4 and 5. The pane 33 is held in place by means of oppositely disposed vertical spacer strips 34, 35 (Fig. 14) together with the horizontal spacer bars 36, 37, the same being held in place preferably by finishing nails, the heads of which 38 areseen in Fig. 12. The windows with two slidable overlapping panes shown are similarly disposed save that the panes are held in a member (not shown) providing a double track or race as is well known in the art.

In the unit shown, the width of each panel at the bottom was 24" and at the top was 22". By employing a total of 22 panels including the door, a dwelling was had of approximately 14 /2 feet diameter at the floor. This gave sufficient space for a kitchen sink 40, a table 41, seating four persons, together with chairs 42, a standard four burner gas range and a refrigerator, and a studio type couch 43 opening up as a double bed. The space shown between the table 41 and sink 4-0 may be used as a bathroom, while a similar sized space to the right of the sink 411 may be used as closet space.

With the exception of the door 45 all side panels are either windowed or not, and are otherwise interchangeable. Similarly the roof panels and roof rafters are respectively alike, whereby their cost is minimized while fulfilling the purpose for which a one room dwelling is suited, as for example, as a camp, tool house, playhouse, field office, etc. It will be noted that by virtue of the construction described, it is possible to constitute the walls and roof of single thickness materials without undue sacrifice of strength.

It will be understood that various of the features shown may be employed without others, and that various changes will occur to those skilled in the art without parting from the spirit of the invention or the scope of the appending claims. For example the walls may be formed of rectangular shape without any taper with some sacrifice of strength.

I claim:

1. In a building construction of equilateral polygonal form having more than four sides, the side walls of said construction comprising wall panels inwardly inclined from the bottom to the top, adjacent edges of said side wall panels being joined to one another by upwardly extending studs having longitudinally extending recesses that form members which frictionally and yieldingly engage and hold the edges of said wall panels whereby the weight of said side panels and studs tends to tighten the union of said studs and the wall panels at the upper ends of said studs, a generally conical roof having radially extending rafters and roof panels between the rafters, said rafters corresponding in number and in location to said studs, means for securing the upper ends of said studs to corresponding of said rafters whereby the load of said roof is supported by said studs with a horizontal force component tending to expand said construction at the upper end thereof, an exterior, flexible, constricting band around said side walls adjacent the upper end thereof opposing said horizontal force, and a poured concrete slab serving as a floor of the construction and having securing elements embodied therein and projecting from the lateral wall thereof and engaging said studs adjacent the lower ends thereof.

2. In a building construction of equilateral polygonal form having more than four sides, the side walls of said construction comprising wall panels inwardly inclined from the bottom to the top, adjacent edges of said side wall panels being joined to one another by upwardly extending studs having longitudinally extending recesses that form members which frictionally and yield ingly engage and hold the edges of said wall panels whereby the weight of said side panels and studs tends to tighten the union of said studs and the wall panels at the upper ends of said studs, a generally conical roof having radially extending rafters and roof panels between the rafters, said rafters corresponding in number and in location to said studs, means for securing the upper ends of said studs to corresponding of said rafters whereby the load of said roof is supported by said studs with a horizontal force component tending to expand said construction at the upper end thereof, an exterior,

flexible, constricting band around said side walls adjacent the upper end thereof opposing said horizontal force, said rafters projecting beyond the ends of the studs to which they are connected, a plurality of bars, each bar underlying and being directly secured to the projecting ends of an adjacent pair of rafters and underlying and supporting the roof panel between the projecting ends of such pair of rafters, to prevent sagging of the roof panels, and means for securing the bottom ends of said studs against outwardly directed horizontal forces.

References Cited in the file of this patent UNITED STATES PATENTS 484,413 Espitallier Oct. 18, 1892 735,485 Farrell Aug. 4, 1903 741,403 Hubbard Oct. 13, 1903 819,129 Ducker May 1, 1906 1,431,272 Van Cott Oct. 10, 1922 1,449,620 Matthews May 27, 1923 1,622,746 Truemper Mar. 29, 1927 1,678,504 Glover July 24, 1928 1,702,340 Gates Feb. 19, 1929 1,750,052 Roberts Mar. 11, 1930 1,830,702 Johnson Nov. 3, 1931 1,955,716 Waller Apr. 17, 1934 2,211,395 Waterman Aug. 13, 1940 2,256,050 Hansen Sept. 16, 1941 2,316,660 Bailey Apr. 13, 1943 2,361,272 Covey Oct. 24, 1944 2,365,891 McLaughlin Dec. 26, 1944 FOREIGN PATENTS 24,445 Great Britain 1893 113,376 Great Britain May 3, 1917 659,123 Germany Apr. 26, 1938 122,984 Sweden Oct. 12, 1948 559,571 Great Britain Feb. 24, 1944 670,705 Great Britain Apr. 23, 1952 

